Group Companies outside Japan
SINO-JAPAN CHEMICAL CO., LTD. (Taiwan)
| Principal business | Manufacture and sale of surfactant and other chemicals |
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A Pre-Start-up Safety Review (PSSR) is recommended by U.S. OSHA rules, the American Institute of Chemical Engineers / Center for Chemical Process Safety (AIChE/CCPS), and the American Petroleum Institute (API). Sino-Japan Chemical has adopted and implemented PSSR as a control method to enhance process safety and facility reliability. In the chemical industry, serious accidents often occur at the time of introducing new equipment, launching new products, changing processes, or changing raw materials. In our plant, we consider PSSR to be important and have established review processes for new equipment, new processes, new materials, and new products. To further enhance the safety of equipment, our safety review team checks engineering measures and management measures prior to start-up, in addition to PSSR.
InterviewRisk assessment of production processes
Senior Specialist and HAZOP Team Leader
Engineering Affairs Section, Manufacturing Department
Sino-Japan Chemical Co., Ltd. (Taiwan)
At the Linyuan Plant, we mainly use HAZOP (Hazard and Operability Analysis) to perform risk management of production processes. With a method taken by a major manufacturer in Taiwan as a guide, we had identified risks, but the method was not suitable for our plant.
Since production processes at our plant differ depending on the step of input of raw materials, replacement, synthesis, etc., we prepared a facility map and an operating procedure manual for each step, carried out HAZOP, and identified potential risks that had been overlooked. Since the fourth quarter of 2022, we have used the above method to carry out a re-assessment of important facilities.
We will continue to pursue safety initiatives based on the philosophy: “Safety takes priority over production.”
NIPPON SHOKUBAI EUROPE N.V. (Belgium)
| Principal business | Manufacture and sale of acrylic acid and superabsorbent polymers |
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In 2022, as in the previous year, Nippon Shokubai Europe organized its second “safety week” during the periodic shut down maintenance in September to remind employees of the importance of ensuring their safety at work.
During this safety week, employees participated in a fire evacuation drill and a confined space rescue drill. For experiential safety education, a presentation about explosions was given by an outside expert. Within well controlled parameters, employees witnessed and experienced several vapor and dust explosions after a thorough explanation about how explosions occur and how to prevent explosions. The participants witnessed how small quantities of chemicals could generate a heat radiation and pressure wave. This event provided employees with a significant learning experience. In addition, initiatives related to the prevention of contamination and quality issues were also carried out.
Nippon Shokubai America Industries, Inc.
| Principal business | Manufacture and sale of superabsorbent polymers, polymers for concrete admixture, water soluble polymers, and acrylic emulsions |
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In 2022, both the Houston and Chattanooga facilities of Nippon Shokubai America Industries (NAII) achieved their goals of zero injuries with loss of workdays and zero environmental violations.
At the Houston facility, the slogan that won the top prize in the annual safety slogan contest was used on hardhat stickers and on a large banner to remind all employees and contractors of the importance of ensuring their safety at work.
At the Chattanooga facility, employees are working on several large-scale projects. The projects at the Chattanooga site and the large-scale periodic maintenance at the Houston site require the cooperation of several contractors in overhauling process equipment, building necessary infrastructure, and resuming production in a timely manner. In 2022, both facilities had no contractor injuries, thus meeting their objectives. Contractor safety will remain a top priority at both NAII locations.
Additionally, as part of its CO2 reduction initiative, NAII switched to green electricity by wind power at the Houston facility through our joint venture American Acryl L.P. from November 2022.
SINGAPORE ACRYLIC PTE LTD
| Principal business | Manufacture and sale of acrylic acid |
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Due to the COVID-19 pandemic, Singapore Acrylic did not hold any physical emergency drills in or after FY2020, and instead only conducted tabletop exercises. We conducted our first emergency drill in June 2022 for the first time in three years, since primary COVID-19 measures had been lifted in Singapore from the second quarter of FY2022, in which we conducted hazmat and confined space drills with an external private fire brigade. Also in December 2022, together with the Singapore Civil Defence Force, we conducted a fire simulation around toluene storage tanks and performed a rescue operation of injured personnel.
In FY2022, to meet the National Environment Agency’s tightened energy management regulations, we decided to implement an ISO 50001 energy management system to better address our energy management shortcomings and to also improve our overall energy consumption. We received professional guidance from an external consultant regarding the necessary documentation and training. We successfully obtained ISO 50001 certification.
NISSHOKU CHEMICAL INDUSTRY (ZHANGJIAGANG) CO., LTD. (China)
| Principal business | Manufacture and sale of superabsorbent polymers |
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Nisshoku Chemical Industry conducted a “Near Miss Kaizen” campaign in 2022, as in the previous year. A total of 181 suggestions (including 33 safety-related ones) were submitted. In the semiannual campaign, the teams that made the most and the second most suggestions per capita are commended.
In September, all employees of the company were given training based on past cases of injuries, and accidents that had occurred at the subsidiary companies of Nippon Shokubai in order to improve their safety awareness.
Twice-a-year emergency drills in collaboration with the local fire department and the emergency response center were conducted in June and December.
First-aid training with an external professional instructor was provided in November.
PT. NIPPON SHOKUBAI INDONESIA
| Principal business | Manufacture and sale of acrylic acid, acrylic esters, and superabsorbent polymers |
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In January 2023, PT. Nippon Shokubai Indonesia conducted emergency drills for a major earthquake disaster, consisting of Emergency Phase 1 (Field team by Shift Operation Members) and Emergency Phase 2 (Office team by Daytime Employees).
On the assumption of a major earthquake, all the employees participated in the Shakeout Drill (Drop, Cover, and Hold on!), in which the participants ensured their safety and then confirmed the safety of other employees and production facilities. In addition, based on a scenario where ethanol leakage and fire were found in the unloading area, the NSI Emergency Response Team that consists of the Office Team and the Field Team launched operations as stipulated in the Procedure. The Office Team was led by the Plant Manager, and the Field Team was led by the Shift Operation Supervisor.
The purposes of these drills are to train employees on initial response against an emergency situation and to enhance the firefighting skills of the Field Team and the command ability of the Office Team in order to contain the spread of damage and ensure safety and security. After the drills, a debriefing was conducted. We will strive to work on the issues identified through the drills and enhance our crisis-control capabilities.
